10)When using the Vw 289d, the measured distance between pinion face and ring gear center line is 58.7Omm less the reading on the dial indicator and less the .40" or l.Omm preload. If the dial indicator reading is 1.63mm you first subtract the preload which gives you .63mm. Now subtract the corrected reading of .63mm from the 58.70mm. You end up with 58.07mm (this is only an example). Now as was
stated before, the actual distance you want is 58.70mm plus the .28mm (example) etched on the gear. Your dimension must be58.98mm, (58.70 + .28) the measurement you made was 58.07mm. Correct pinion shim will be the difference between these two figures.
58.98= what you want
-58.07= what you have
.91 = size of shim you need
Make this shim adjustment as close to your measurement as possible, tolerance is only .02mm.
Next you need to measure the distance between the inner races of the differential side bearings. Side plate to opposite side plate distance with bearings.

1)Affix a dial indicator to set above the center of the installed VW289d so that the stem contacts the instrument/tool. Set dial at zero. (VW 297 can be used as a mount.) An axle tube retainer stud on the side plate can be used as a mounting point.
2)Rotate the transmission case so that the opposite side plate is up. Let the VW 289d fall by its own weight.
3)Record the measurement given on the dial indicator.
4)When using the VW 289d, the distance between the shoulders of the instrument are 107.88mm. If the dial indicator measurement was 1.75mm the total distance between the differential side bearings equals 107.88 + 109.63mm. This measurement is used to set up ring gear adjustment.

Note:This measurement can be made using a modified ring gear
carrier.

Removal of special instruments and /or tools can be done now. Permanently install pinion and gear box into main case using proper shim this time. Don't forget to adjust shift forks first. Now the ring gear must b e adjusted for proper ring - pinion tooth contact.

Measure the width of the ring gear carrier between its bearing flanges. Either use caliper squares and a magnifying glass to make sure you make an accurate reading or use VW 287a (a machine shop can mic. it for you). If the ring gear side of the differential is recessed (Use a new differential bearing shim - mic. it for accuracy). Subtract the spacer measurement from your reading to get correct distance.

Note: In the following steps use VW 297 or make up a suitable device to adjust ring gear to backlash limits. You will need two dial indicators also. One to measure backlash and one to measure sideways movement of the ring gear.

What we will be doing is moving the ring gear and its carrier toward the pinion gear until backlash is held within the clearance of .007" - .010" or .17mm - .25mm. If you are using VW 297 proceed as follows:

next