AUDI A6 1999 C5 / 2.G 01V Transmission Drive Pinion And Ring Gear Adjust Owner's Manual

39-184

- Remove drive pinion and large tapered roller
bearing outer race and install together with
determined adjustment shim "S3" and spacer
sleeve Page 39
-159
onward.

- Insert small tapered roller bearing inner race and
tighten nut for drive pinion until specified friction
torque is attained Fig. 11
, page 39
-164
.

Notes:

Do not grease new tapered roller bearings
additionally for friction torque measurement.
The bearings are already greased with a
special oil from the factory.
Increase torque slowly and measure friction
torque multiple times. If the specified friction
torque is surpassed, replace spacer sleeve and
repeat adjustment! Any spacer sleeve that has
been pressed together too far one time must be
replaced.

- Adjust friction torque to following values:
New bearings
Run-in bearings
1)
200 to 250 Ncm 30 to 60 Ncm

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1) have been run in at least 50 km
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39-185

Perform check measurement

Checking dimension "r"

- Rotate drive pinion at least 5 complete
revolutions in both directions.

- Insert universal mandrel and perform check measurement.

If adjustment shims were determined correctly, dial indicator must
indicate deviation "r" with a tolerance of 0.04 mm (reading
counterclockwise in red number display).

- Peen drive pinion nut using mandrel.
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39-186

Ring gear, adjusting

(Adjusting differential)
Procedures after which the ring gear must be
adjusted Adjustment overview page 39
-
170
.

Notes:

Tapered roller bearings for differential are low-
friction bearings. Therefore friction torque can
only be used for check measurement in a
limited way. A correct adjustment is only
possible by determining the total thickness
"Sges".
Do not grease new tapered roller bearings
additionally for friction torque measurement.
The bearings are already greased with a
special oil from the factory.

Total shim thickness "Stotal" for adjustment
shims "S1" + "S2", determining
(adjust preload of tapered roller bearing for
differential)
Drive pinion removed or ring gear detached
from differential housing
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- Pry out drive flange seal using tire iron.

- Remove tapered roller bearings for differential
and remove adjustment shims page 39
-136
.
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39-187

- Press tapered roller bearing outer race for left
side of differential housing (housing side)
together with shim "S2" into differential housing
Page 39
-144
. Use a shim "S2*" with a 1.00
mm thickness for measurement purposes (1
shims with 0.80 and 1 with 0.20 mm).

Note:
All measurements are performed with shim S2
with 1.00 mm thickness. The shim will be
indicated by "S2*" in the following procedures.
After determining backlash, S2* is replaced by
final shim S2.

- Press in tapered roller bearing outer race for
right side (cover side) of differential without
adjustment shims to stop Fig. 8
, page 39
-
136
.

- Insert differential in housing. Ring gear is on the
right side (cover side).

- Install cover and tighten bolts to 25 Nm.

- Install VW521/4 locking sleeve and 521/8 sleeve press tool into
differential housing on housing side.
- Rotate cover side of differential housing upward.
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39-188

- Turn differential 5 rotations in each direction to
seat the tapered roller bearing.

- Place VW385/17 magnetic plate onto
differential.

- Install measuring tools.
A - Dial gauge extension approx. 30 mm long
B - Hex bolt M8 x 45
- Set dial gauge extension onto center of VW 385/17 magnetic plate.
- Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.

Note:
If measurement is repeated, differential must first be rotated 5 complete
revolutions in both directions again to seat tapered roller bearing. - Lift the differential without turning it, read play on dial indicator and
note.

Measured value in the following example: 0.50 mm
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39-189

Formula:
"Stotal"
=
"S2*" + measured value + bearing
preload

Example:

Installed shim(s) "S2*" 1.00
mm
+ Measurement 0.50
mm
+ Bearing preload (constant) 0.30
mm
= Total shim thickness "Stotal"for shims
"S1" + "S2"
1.80
mm
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39-190

Determining thickness of shim "S1*"

Notes:

"S1*" is used for the initial measurement. After
determining backlash, "S1*" is replaced with
final shim "S1".
The total shim thickness "Stotal" remains
unchanged.

Formula:
"S1*"
=
"Stotal" - "S2*"

Example:


Total shim thickness "Stotal"for shims
"S1" + "S2"
1.80
mm
- Installed shim(s) "S2*" 1.00
mm
= Thickness of shim "S1*" 0.80
mm

- Determine adjustment shim(s) as closely as
possible according to table page 39
-195
.
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39-191

Measuring friction torque (check
measurement)

Drive pinion removed
Differential installed with shims "S1*" and
"S2*"

Friction torque specified values: 1) have been run in at least 50 km
Notes: - Position torque gauge 0 to 600 Ncm -A- on differential.
- Read friction torque.New bearings
Run-in bearings
1)
150 to 300 Ncm 30 to 60 Ncm
Tapered roller bearings for differential are low-friction bearings.
Therefore friction torque can only be used for check measurement in a
limited way. A correct adjustment is only possible by determining the
total thickness "Sges". Do not grease new tapered roller bearings additionally for friction
torque measurement. The bearings are already greased with a special
oil from the factory. For a new adjustment of the gear set, the drive pinion adjustment
Pa
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