AUDI A4 1998 B5 / 1.G 01W Transmission Pinion Shaft Ring Gear Adjustment Workshop Manual

39-29


Pinion shaft and ring gear,
adjusting

Notes:

Careful adjustment of the pinion shaft and ring
gear is essential for the service life and smooth
running of the final drive. For this reason, the
pinion shaft and the ring gear are matched
together during manufacturing and checked to
ensure a good mesh pattern and quiet running
in both directions of rotation. The position of
quietest running is found by moving the pinion
shaft in an axial direction, and at the same time
lifting the ring gear out of the zero-play mesh
position by the amount necessary to maintain
the backlash within the specified tolerance.
The goal of the adjustment is to reproduce the
setting for the quietest possible running, as
obtained on the test machine during production.
The deviation, or tolerance "r" which is based
on the master gauge "R0" is measured for the
final drive sets supplied as replacement parts
and marked on the outer circumference of the
ring gear. The final drive set (pinion shaft and
ring gear) must only be replaced together as a
matched pair.
Observe the general repair instructions for
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tapered roller bearings and adjustment shims.
The friction torque measurement only serves as
a final check of the adjustment.
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39-30


Adjustment and marking of final drive gear
sets

1 -
Identification "0397" signifies an Oerlikon
gear set with a ratio of 37:9
2 -
Pairing number (312) of final drive gear
set
3 -
Deviation (tolerance) "r" is based on the
test machine master gauge used during
production. The deviation "r" is always
given in 1/100 mm. Example: 25 signifies
"r" = 0.25 mm
Ro - Length of test machine master gauge
Ro - Ring gear diameter 170 mm = 54.95
mm
Ro - Ring gear diameter 180 mm = 59.65
mm
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39-31


R - Actual dimension between ring gear
axis and face of pinion shaft in position
of quietest running for this gear set
Vo - Hypoid offset
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39-32


Installation position of adjustment shims

Note:
List of adjustments when replacing individual
components of transmission Page 39
-33
.
S1 - Adjustment shim for ring gear in final
drive cover
S2 - Adjustment shim for ring gear in
transmission housing
S3 - Adjustment shim for pinion shaft in
transmission housing
S4 - Adjustment shim for pinion shaft in
transmission cover
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39-33
List of adjustments

Note:
If repairs have been carried out on the transmission, it is only necessary to adjust the pinion shaft, ring gear or gear set if
components have been replaced that directly influence the final drive adjustment. To avoid unnecessary adjustments, refer to
the following table:

Component to be adjusted:

Component replaced:

Ring gear
"S1"+ "S2" 1)

Page 39
-52

Pinion shaft
"S3"+ "S4" 1)
via deviation "r"
Page 39
-35

Pinion shaft
"S4" 1)

Page 39
-49

Backlash measurement

Page Page 39
-58

Transmission housing 3) X X X
Transmission cover X
Differential housing X X
Tapered roller bearing for pinion shaft X X
Tapered roller bearing for differential X X
Gear set 2)
X X X
Cover for final drive X X 1) Adjustment shims: installation position Page 39
-32
.
2) Replace pinion shaft and ring gear together as a set only.
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3) If the transmission housing is replaced, adjust input shaft Page 35
-17
.
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39-34

Sequence for adjusting gear set


If pinion shaft and gear ring have to be adjusted, the following sequence
is recommended for maximum efficiency:
Note:
Overview of components and shims Page 39
-32
. 1.) Determine total shim thickness Stotal for S1 + S2 (adjusting preload
for tapered roller bearing for differential) Page 39
-53
.
2.) Determine total shim thickness Stotal for S3 + S4 (adjusting preload
for tapered roller bearing for pinion shaft) Page 39
-37
.
3.) Distribute total shim thickness Stotal for S3 + S4 so that the
dimension between the center of the gear ring and the face of the
pinion shaft equals dimension "R" which was determined during
production Page 39
-45
.
4.) Distribute total shim thickness Stotal S1 + S2, so that the specified
backlash between ring gear and pinion shaft is maintained Page
39
-61
.
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39-35

Pinion shaft, adjusting

Procedures, after which the pinion shaft must be
adjusted Page 39
-33
, table

Special tools and equipment

VW204B installation tool for crankshaft seal
VW296 removal tool
VW385 universal gauge
VW385/1 measuring bar
VW385/2 centering disc (for transmissions
without polygon bearing)
VW383/3 centering disc (2x)
VW385/14 measuring rod
VW385/15 extension pin
VW385/30 master gauge (adjustable)

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VW385/33 end gauge
VW387 Dial Gauge Holder
VW401 thrust plate
VW407 punch
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