AUDI A4 1999 B5 / 1.G 01A Transmission Total Shim Thickness Workshop Manual

39-41


Speedometer Vehicle Speed
Sensor (VSS), removing and
installing

Total shim thickness Stotal for
shim S3 + S4, determining
Adjust preload of tapered roller bearings for
pinion shaft with hollow shaft

Differential removed

Note:
Illustration shows hollow shaft without gears. The adjustment of the pinion
shaft can be done with or without gears. - Press inner race -1- for double tapered roller bearing onto pinion shaft
and secure Page 35
-21
.
- Position needle bearing -2-.
- Install circlip 3 onto hollow shaft and press on inner race for tapered
roller bearing -4- Page 35
-21
.
- Insert pinion shaft in hollow shaft.
Pa
ge 1 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

39-42


- Install double tapered roller bearing outer race for pinion shaft in
transmission housing without shims Fig. 3, Page 35
-31
.

Notes: - Install tapered roller bearing outer race for pinion shaft in transmission
cover together with shim S4* (1.0 mm thick) Fig. 8, Page 35
-33
.
A shim S4 with a thickness of 1.0 mm is installed for initial
measurement. It is referred in the following text as S4*. After
determining measurement "e", S4* is replaced with the appropriate
shim S4. When taking measurements, always install the rubber washer together
with the pressure plate for the rubber washer Page 35
-29
.
- Install fully assembled pinion shaft with hollow shaft into transmission
housing.
Pa
ge 2 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

39-43

- Install transmission cover and tighten bolts to 22
Nm (16 ft lb).

- Turn transmission so transmission cover faces
downward.

- Press down on face of pinion shaft using VW296 removal tool until
tapered roller bearing outer race contacts transmission cover.
- While still maintaining pressure, rotate pinion shaft 5 turns in each
direction opposite hollow shaft to settle double tapered roller bearing.
- Rotate pinion shaft together with hollow shaft 5 turns in each direction
to settle tapered roller bearing.

Note:
The dial indicator extension must contact the machined surface on the
face of the pinion shaft. - Assemble measuring equipment, use 30 mm dial indicator extension.
- Set dial indicator (3 mm measuring range) to "0" with 1 mm preload.
-
Turn transmission 180 so transmission cover faces upward.
Pa
ge 3 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

39-44

- Rotate pinion shaft together with hollow shaft 5
turns in each direction to settle tapered roller
bearing. Otherwise measurement will not be
correct.

Note:
If the measurement has to be repeated, first rotate the pinion shaft with
hollow shaft again 5 turns in each direction to settle the tapered roller
bearing. Then set the dial indicator to "0" again with 1 mm preload. - Read off and note play indicated on dial indicator.
Measurement in example: 0.45 mm
Formula:
Stotal
=
S4* + measurement + bearing preload
Example:

Inserted shim S4* 1.00 mm
+ Measurement (example) 0.45 mm
+ Bearing preload (constant) 0.15 mm
=
Total shim thickness Stotal for S3 + S4
1.60 mm
Pa
ge 4 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

39-45

Determining thickness of shim S3*

Formula:
S3*
=
Stotal - S4*

Example:


Total shim thickness Stotal for S3 +
S4
1.60
mm
- Inserted shim S4* 1.00
mm
= Thickness of shim S3* 0.60
mm

- Remove double tapered roller bearing outer
race, install shim S3* in transmission housing
and re-install outer race Fig. 3, Page 35
-31
.

- Insert fully assembled pinion shaft into
transmission housing again.

- Install transmission cover and tighten bolts to 22
Nm (16 ft lb).

-
Rotate pinion shaft together with hollow shaft 5
turns in each direction, then rotate pinion shaft
Pa
ge 5 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

separately in relation to hollow shaft 5 turns in
each direction, to settle tapered roller bearings.
Pa
ge 6 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

39-46


- Install measuring tools and secure to transmission housing using bolt
(arrow).
- Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
- Loosen transmission cover bolts and turn pinion shaft several times.
- If correct shims have been selected, dial indicator will now indicate the
following value:
0.05-0.15 mm
- Tighten transmission cover bolts again to 22 Nm (16 ft lb).
- Remove measuring tools.
- To settle tapered roller bearings, rotate pinion shaft together with
hollow shaft 5 turns in each direction, then rotate pinion shaft
separately in relation to hollow shaft 5 turns in each direction.
Pa
ge 7 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

39-47

Determining measurement "e"

Note:
Measurement "e" is required to determine the
final shim thickness of S3 and S4.

- Set adjustment rings of universal mandrel using VW385/1 measuring
bar to the following measurements:

Dimension a: 35 mm (1.378 in.)
Dimension b: 75 mm (2.953 in.)

- Assemble VW385/1 measuring bar as illustrated:

Dial indicator extension -A-, 6.5 mm long
VW385/30 master gauge-adjustable
- Set VW385/30 master gauge to Ro = 54.95 mm (2.163 in.)for 170 mm
(6.693 in.) diameter ring gear and install on universal mandrel.
- Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
Pa
ge 8 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

39-48


Note:
Make sure gauge contact surface is precisely installed and free of oil. - Place end gauge on face of pinion shaft.

- Remove master gauge and install measuring mandrel into transmission
housing.
Dial indicator extension -A- = 6.5 mm long must be installed. The VW385/3 centering disc faces cover for final drive
- Install differential cover and tighten 4 bolts to 22 Nm (16 ft lb).
- Using adjustable ring, pull 2nd VW385/3 centering disc out as far as
possible, so mandrel can only just be turned by hand.
Pa
ge 9 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

39-49


Measurement in following example "e" = 0.26 mm (red scale)
Note:
After removing universal mandrel, and with VW385/30 master gauge in
place, check dial indicator again to see if it indicates "0" with 2 mm
preload, otherwise correct adjustments.
Determining thickness of shim "S3"
Notes:
The deviation "r" (tolerance) related to the VW385/30 master gauge "Ro"
is measured for the final drive sets supplied as replacement parts and
marked on the outer circumference of the ring gear. - Turn mandrel until dial indicator plunger tip touches end gauge on
pinion shaft head, measure maximum runout (return point).
Formula:
S3
=
S3* + r + e
(-e- in black scale)
or
S3
=
S3* + r - e
(-e- in red scale)
Pa
ge 10 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7