Dismantling and assembling planetary gearbox
Planetary gearbox adjustments - overview
1. I- Planet carrier
◆ A - Shim
◆ Determining thickness =>
Adjusting planet carrier,
Page 37-129
2. II - Reverse gear brake -
B1-
◆ B - Shim
◆ Determining thickness
=> Adjusting reverse gear
brake -B1-, Page 37-137
3. III - Clutch play
◆ C - Shim
◆ Determining thickness =>
Adjusting clutch play
between -K1- and -K2-,
Page 37-145
4. IV - 2nd and 4th gear
brake -B2-
◆ D - Outer plate
◆ Determining thickness
=> Adjusting 2nd and 4th
gear brake -B2-, Page 37-
152
Dismantling and assembling planetary gearbox
I - Adjusting planet carrier
Overview of components
Note:
When adjusting planet carrier, install
components in gearbox housing without
shim (Item 18).
1. Input gear
◆ Do not remove to adjust
the planet carrier
2. Axial needle bearing washer
◆ Installation position:
smooth side faces toward
input gear
3. Axial needle bearing
4. Axial needle bearing washer
5. O-ring
◆ Renew
◆ Insert into planet carrier
=> Assembling planet
carrier, Page 37-111
6. Planet carrier
7. Gearbox housing
◆ With input gear and axial
needle bearing
◆ Axial needle bearing
remains in input gear
◆ If axial needle bearing is
damaged => Removing
and installing input gear,
Page 39-17
8. Small sun gear
9. Washer
10. Axial needle bearing
11. Large sun gear
12. Washer
◆ Insert into large sun gear
=> Assembling planetary
gearbox, Page 37-111
13. Axial needle bearing
14. Large input shaft
15. Axial needle bearing
16. Needle bearing
17. Small input shaft
18. Shim
◆ Do not install in planet
carrier when adjusting
19. Washer
20. Bolt for small input shaft - 30
Nm
Special tools and workshop equipment required
◆ Measuring device VW 382
◆ Dial gauge
→ Determining shim -A-
‒ To adjust planet carrier, install all components (items
37-129.
‒ Engage parking lock.
‒ → To slacken bolt for small input shaft, insert
screwdriver in holes of large sun gear.
Note:
If the parking lock cannot be engaged, use a second
screwdriver to hold the large input shaft.
‒ → Install bolt -1- for small input shaft together with
washer -2- but without shim -3-.
‒ Tighten bolt to 30 Nm.
‒ → Set up dial gauge so that tip of gauge is positioned
on centre of bolt head with 1 mm preload.
‒ Zero dial gauge.
‒ Move small input shaft up and take reading.
● Reading in following example: 2.00 mm.
‒ Determine size of shim(s) according to table. Part
Numbers
=> Parts catalogue
Table of shims -A-
Gauge Gauge
reading Shim (mm) reading Shim (mm)
(mm) (mm)
1.26 ... 2.26 ...
1.0 1.0 + 1.0
1.35 2.35
1.36 ... 2.36 ...
1.1 1.0 + 1.1
1.45 2.45
1.46 ... 2.46 ...
1.2 1.1 + 1.1
1.55 2.55
1.56 ... 2.56 ...
1.3 1.1 + 1.2
1.65 2.65
1.66 ... 2.66 ...
1.4 1.2 + 1.2
1.75 2.75
1.76 ... 2.76 ...
1.5 1.2 + 1.3
1.85 2.85
1.86 ... 2.86 ...
1.6 1.3 + 1.3
1.95 2.95
1.96 ... 2.96 ...
1.7 1.3 + 1.4
2.05 3.05
2.06 ... 3.06 ...
1.8 1.4 + 1.4
2.15 3.15
2.16 ... 3.16 ...
1.9 1.4 + 1.5
2.25 3.25
‒ Remove small input shaft bolt.
‒ → Fit determined shim -3- onto small input shaft
(arrow).
Example:
If the reading is 2.00 mm use a shim with a thickness of 1.7
mm.
‒ Insert bolt -1- for small input shaft together with washer
-2-.
‒ Tighten bolt to 30 Nm.
‒ Carry out planet carrier check measurement => Page
37-136.
Planet carrier check measurement
‒ → Insert dial gauge in VW 382/7 and place the tip on
the bolt of the small input shaft.
‒ Move small input shaft up and down and take reading
of play on dial gauge.
● Play: min. = 0.23 mm; max. = 0.37 mm.
Note:
If the planet carrier has been adjusted with reverse gear
brake -B1- and free wheel removed then before installing
planet carrier install reverse gear brake -B1-, => Assembling
planetary gearbox, Page 37-111.
Dismantling and assembling planetary gearbox
II - Adjusting reverse gear brake -B1- - overview
Overview of components
1. Gearbox housing
◆ With input gear and planet
carrier installed
2. Shim
◆ 1 or 2 shims can be
installed
3. Outer plate -B1-
◆ Quantity => from Page 00-
3
4. Inner plate -B1-
◆ Quantity => from Page 00-
3
5. Pressure plate
◆ Installation position: Flat
side faces toward plates
◆ Replacement part must be
selected according to
gearbox code letters
(different identifications)
6. Dished washer
◆ Installation position:
Convex side faces toward
free wheel
7. Free wheel with -B1- piston
8. Circlip
Special tools and workshop equipment required
◆ Press plate VW 402
→ Determining thickness of shim -B-
The thickness of the shim depends on the size of gap "x".
Gap "x" is calculated using the following formula:
x = K + (l /2) - m
B = Shim
x = Gap
Position of piston in free wheel;
I =
calculating "l"=> Page 37-141
Height of plate set including pressure
m = plate;
calculating "m" => Page 37-142
Constant value: 30.5 mm; "K" is
determined by installation height in
K =
gearbox housing and is not
adjustable.
Calculating "l"
‒ Press piston into free wheel as far as stop.
‒ → Place straightedge -A- onto outer race of free wheel
and hold in position -arrows-.
‒ Use depth gauge -B- to measure down to inner edge
of piston.
Example:
Reading 51.8 mm
- Straightedge 48.2 mm
= Calculated size "I" 3.6 mm
Calculating "m"
‒ → Place straightedge "A" on thrust plate.
‒ Compress set of plates including pressure plate in
direction of arrow and measure the thickness of plate
set with depth gauge "B".
Example:
Reading 77.2 mm
- Straightedge 48.2 mm
= Calculated size "m" 29.0 mm
Example for calculating gap:
x = K + (l /2) - m
x = 30.5 + (3.6 / 2) - 29.0 = 3.3 mm
‒ Determine size of shim(s) according to table. Part
Numbers
=> Parts catalogue
Table of shims -B-
Gap Gap
Shim(s) (mm) Shim(s) (mm)
"x" (mm) "x" (mm)
2.36 ... 3.36 ...
1.0 1.0 + 1.0
2.45 3.45
2.46 ... 3.46 ...
1.1 1.0 + 1.1
2.55 3.55
2.56 ... 3.56 ...
1.2 1.1 + 1.1
2.65 3.65
2.66 ... 3.66 ...
1.3 1.1 + 1.2
2.75 3.75
2.76 ... 3.76 ...
1.4 1.2 + 1.2
2.85 3.85
2.86 ... 3.86 ...
1.5 1.2 + 1.3
2.95 3.95
2.96 ... 3.96 ...
1.6 1.3 + 1.3
3.05 4.05
3.06 ... 4.06 ...
1.7 1.3 + 1.4
3.15 4.15
3.16 ... 4.16 ...
1.8 1.4 + 1.4
3.25 4.25
3.26 ...
1.9
3.35
‒ After determining shim for -B1- carry out check
measurement.
Reverse gear brake -B1- check measurement
‒ Install parts up to free wheel and secure with circlip
=> Assembling planetary gearbox, Page 37-111.
‒ → Use a feeler gauge -A- to measure play between the
plates (accessible through gap next to valve body
flange).
● Play: min. = 1.25 mm; max. = 1.55 mm.
