AUDI A6 1999 C5 / 2.G 01E Transmission Final Drive Pinion Adjustment User Guide

39-47


Determining thickness of shim "S3"
Note: - Turn mandrel until dial gauge plunger tip touches end measuring plate
on drive pinion head, then measure maximum deflection (return point).

Measurement in following example: "e" = 0.16 mm (in red scale)
Formula:
"S3"
=
"S3*" + "r" + "e"
("e" in black scale)
or
"S3"
=
"S3*" + "r" - "e"
("e" in red scale)
The deviation "r" related to the master gauge "Ro" is measured for the
final drive sets supplied as replacement parts and inscribed on outer
circumference of ring gear. If measurements are obtained on red scale then subtract value "e."If measurements are obtained on black scale then add value "e."
Pa
ge 11 of 16 Drive
pinion, ad
justin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.39.7

39-48

Example:

Inserted shim "S3*" 1.05 mm
+ Deviation "r" 0.38 mm
- Determined "e" (in red scale)
0.16 mm
=
Thickness of shim "S3" 1.27 mm

- Determine shim(s) from table.

Parts catalog
The following shims are available for "S3"

Shim thickness (mm)
1)
0.45 0.60 0.75
0.50 0.65
0.55 0.70

1) Using the shim tolerance variations it is
possible to find the exact shim thickness
required, insert two shims if necessary.
Pa
ge 12 of 16 Drive
pinion, ad
justin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.39.7

39-49

Determining thickness of shim "S4"

Formula:
"S4"
=
"S
total
" - "S3"

Example:


Total shim thickness "S
total
"
for "S3" + "S4"
2.05 mm
- Thickness of shim "S3" 1.27 mm
= Thickness of shim "S4" 0.78 mm

- Determine shim(s) from table.

Parts catalog

The following shims are available for "S4"

Shim thickness (mm)
1)
0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Pa
ge 13 of 16 Drive
pinion, ad
justin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.39.7

1) Using the shim tolerance variations it is
possible to find the exact shim thickness
required, insert two shims if necessary.
Pa
ge 14 of 16 Drive
pinion, ad
justin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.39.7

39-50

Performing check measurement

Checking dimension "r"

- Install drive pinion with determined shims "S3"
and "S4" and turn 5 turns in both directions.

Note:
Then, (after removing universal mandrel) check again that the dial gauge,
with master gauge VW 385/30 in place, indicates "0" with 2 mm preload,
otherwise correct adjustments. - Insert universal mandrel, Page 39
-45
, "determining measurement
'e'" and perform check measurement.
- Read off dial gauge anti-clockwise (red scale).

If the shims have been correctly selected, the deviation "r" (marked
on outer circumference of ring gear) must be shown - within a
tolerance of 0.04 mm
Pa
ge 15 of 16 Drive
pinion, ad
justin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.39.7

39-51

Measuring friction torque (check)

Note:

Drive pinion/hollow shaft tapered roller bearings
are low friction bearings. Therefore the frictional
torque has only a limited use as a check.
Correct adjustment is only possible by
determining the total shim thickness "S
total
."

Do not additionally oil new tapered roller
bearing to perform the frictional torque
measurement. These bearings have already
been treated with a special oil by the
manufacturer.

Frictional torque specification: - Fit torque gauge 0-600 Ncm -A- onto drive pinion.
B - Socket
- Insert tensioning sleeve 3116.New bearings
Used bearings
80-150 Ncm 30-60 Ncm
Pa
ge 16 of 16 Drive
pinion, ad
justin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.39.7